The present disclosure is generally directed to a door assembly having a concealed or hidden door closer. In particular, the hidden door closer may be inserted or housed in a pocket in a drip cap mounted to the upper header of a framed door opening. The inserted door closer is attached to a closer arm that is connected to a sliding attachment mounted to a slide track that is associated with an upper horizontal rail of the door. In use, the door closer provides sufficient force to the closer arm to move the door from an opened position to a closed position.
Door closers have been used for many years. These closers run the gamut from weights which travel about a pulley to open and close the door to spring-loaded hinges in which a torsion spring is coaxial with the hinge pin. Other closers, for example, use one or more externally mounted pneumatic or hydraulic cylinders while still other closers use a complex hydraulic mechanism in combination with a folding linkage attached to the top of the door. Not only do these reported closer designs vary in effectiveness in reliably closing the door, many of these closer designs also detract from the aesthetic appearance of the door since they are mounted as an appendage to the surface of the door.
Hollow interior portions of a wide variety of doors, such as screen doors, storm doors, exterior doors, or interior doors, lend themselves to the potential of mounting a door closer in the interior structure of these doors. U.S. Pat. No. 5,829,508, for example, reports an interior mounted door closer with a spring-mounted, sliding closer mechanism fitted in the upper part of the door. This reported closer includes a number of moving parts that are installed in the upper internal section of the door. There is a need for a hidden closer that is simply easier to install and use than previously reported closers.
The present disclosure describes various embodiments of a concealed or hidden door closer that is installed in an upper rail of a door assembly. In some embodiments, the door frame and door closer components are configured to allow the door assembly to be readily installed as either a left or a right hand hinged door.
In one embodiment (2 Closer Pockets in Drip Cap), this disclosure describes a door assembly, comprising:
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- a door having first and second vertical stiles attached to upper and lower horizontal rails;
- a horizontal slide track associated with the upper horizontal rail;
- a drip cap having a horizontal body with first and second ends having two closer pockets located in regions of the horizontal body adjacent to the first and second ends;
- a closer insertable into one of the pockets of the drip cap comprising a closer attachable to the drip cap, and a vertical pinion rotatably connected to an internal biasing mechanism such as a biasing spring and having at least one connecting stud extending through the closer body, wherein the vertical pinion provides sufficient rotational force to move the door from an opened position to a closed position; and
- a closer arm having an attachment fixture on one end of the closer arm attachable to the vertical pinion connecting stud and a slide fixture on an opposite end of the closer arm insertable into the slide track.
In this embodiment as well as in other embodiments described below, the door assembly may be configured and/or oriented to be installed as either a left hinged or a right hinged door. In a left hinged door the vertical hinge stile and vertical hinge frame are on the left side of the door when viewed from the exterior side of the door, while in a right hinged door the vertical hinge stile and vertical hinge frame are on the right side of the door. In some embodiments, for example, the door frame may be essentially symmetrical about a vertical axis with both the left and right vertical stiles capable of receiving or being fitted with an external latch mechanism for either a left hinged or a right hinged door. Alternatively, an installer may drill or cut either the right or left vertical stile at the assembly site so that the vertical stile may receive or be fitted with an internal latch mechanism for either a left hinged or right hinged door. In other embodiments, for example, the door frame may be essentially symmetrical about a horizontal axis and the vertical latch stile may include a precut latch pocket. In this embodiment with two closer pockets in a drip cap, the door frame may be oriented with the vertical latch stile to the right side of the door and the vertical latch stile may receive or be fitted with an internal latch mechanism. Alternatively, this door frame may be oriented with the vertical latch stile to the left side of the door by rotating the door frame 180° top-to-bottom for a right hinged door (while maintaining the orientation of the exterior and interior for the left hinged door). Those skilled in the art will understand that there are other configurations and/or orientations of the door assemblies of this disclosure that may be installed as both left hinged or right hinged doors. Various configurations and/or orientations for left hinged and right hinged doors are described below, for example, when referring to FIGS. 1-3.
In another embodiment (Channel in Drip Cap), this disclosure describes a door assembly, comprising:
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- a door having one or more vertical stiles attached to upper and lower horizontal rails;
- a horizontal slide track associated with the upper horizontal rail;
- a drip cap having a horizontal body with first and second ends having an internal channel extending between the first and second ends;
- a closer insertable into the internal channel of the drip cap comprising a closer body attachable to the drip cap, and a vertical pinion rotatably connected to an internal biasing mechanism such as a biasing spring and having at least one connecting stud extending through the closer body, wherein the vertical pinion provides sufficient rotational force to move the door from an opened position to a closed position; and
- a closer arm having an attachment fixture on one end of the closer arm attachable to the vertical pinion connecting stud and a slide fixture on an opposite end of the closer arm insertable into the slide track.
Those skilled in the art will readily recognize that this embodiment of a door assembly may be configured and/or oriented for either a left hinged or a right hinged installation as described above.
In still another embodiment (Center Closer Pocket in Drip Cap), this disclosure describes a door assembly, comprising:
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- a door having first and second vertical stiles attached to upper and lower horizontal rails;
- a horizontal slide track associated with the upper horizontal rail;
- a drip cap having a horizontal body with first and second ends having a closer pocket in a center region of the horizontal body between the first and second ends;
- a closer insertable into the pocket of the drip cap comprising a closer body attachable to the drip cap, and a vertical pinion rotatably connected to an internal biasing mechanism such as a biasing spring and having at least one connecting stud extending through the closer body, wherein the vertical pinion provides sufficient rotational force to move the door from an opened position to a closed position; and
- a closer arm having an attachment fixture on one end of the closer arm attachable to the vertical pinion connecting stud and a slide fixture on an opposite end of the closer arm insertable into the slide track.
Those skilled in the art will readily recognize that this embodiment of a door assembly may be configured and/or oriented for either a left hinged or a right hinged installation as described above.
In still another embodiment (Left or Right Hinged Door with Pocket in Drip Cap), this disclosure describes a door assembly, comprising:
-
- a door having first and second vertical stiles attached to upper and lower horizontal rails;
- a horizontal slide track associated with the upper horizontal rail;
- a drip cap having a horizontal body with first and second ends having one closer pocket located in a region of the horizontal body adjacent one of the ends of the drip cap for either a left hinged or a right hinged door assembly;
- a closer insertable into the pocket of the drip cap comprising a closer body attachable to the drip cap, and a vertical pinion rotatably connected to an internal biasing mechanism such as a biasing spring and having at least one connecting stud extending through the closer body, wherein the vertical pinion provides sufficient rotational force to move the door from an opened position to a closed position; and
- a closer arm having an attachment fixture on one end of the closer arm attachable to the vertical pinion connecting stud and a slide fixture on an opposite end of the closer arm insertable into the slide track.
In the embodiments set out above, the door may be in a variety of configurations such as, for example, a full view door, a high view door, or a mid-view door. The described doors may also be interchangeable doors or self-storing doors. For example, in some embodiments the glass and screen panels may be exchanged seasonally. Alternatively, the glass and screen panels may be stored in designated sections of the door and either the glass or screen may be moved into place when it is desired to have either the screen or the glass in view.
In addition, the embodiments set out above may include additional components. In some of the described embodiments, the door assembly may include a vertical hinge frame attached to at least one of the vertical stiles to provide either the left or right hinged door. In other embodiments, the door assembly may also include latching components attachable to at least one of the vertical stiles where the latch mechanism is externally mounted to at least one of the vertical stiles, or alternatively is internally mounted in a latch pocket in at least one of the vertical stiles. In still other embodiments, the door assembly includes a vertical latch frame attached to a door jamb adjacent at least one of the vertical stiles where the vertical latch frame has optional fixtures to receive the latching components of the latch mechanism. In yet other embodiments, the door assembly may include a slide track that is an integral component of one or both of the upper and lower horizontal rails, or alternatively a slide track that is a component associated with or attachable to the upper horizontal rail.
Further, various embodiments of a closer may be used with the disclosed door assemblies. The closer, for example, may include an internal biasing mechanism such as a biasing spring that provides a torsional force or linear force. Other alternative biasing mechanisms may include compressible and/or expandable materials such as fluids or gases which may be used alone or in combination with, for example, biasing springs. In addition, the closer may be set to close the door at a consistent speed or a variable speed. In some embodiments, the closer may have a vertical pinion that has upper and lower connecting studs extending through a top and bottom of the closer body. In this embodiment, a lower connecting stud will rotate clockwise when the closer is in a first orientation in the closer pocket, and counterclockwise when the closer is in a second orientation in the closer pocket. In other embodiments, the closer may have a connecting stud that rotates either clockwise or counterclockwise when displaced from a center biased position. In still other embodiments, the closer may include a dampener component to control the closing speed of the door.
In an alternative embodiment, this disclosure describes a door assembly kit comprising:
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- a door having first and second vertical stiles attached to upper and lower horizontal rails;
- a horizontal slide track associated with the upper horizontal rail;
- a drip cap having a horizontal body with first and second ends optionally having two closer pockets located in regions of the horizontal body adjacent to the first and second ends, an internal channel extending between the first and second end, a closer pocket in a center region of the horizontal body between the first and second ends, or one closer pocket located in a region of the horizontal body adjacent one of the ends of the drip cap;
- a closer insertable into one of the pockets or the channel of the drip cap comprising a closer body attachable to the drip cap, and a vertical pinion rotatably connected to an internal biasing mechanism such as a biasing spring and having at least one connecting stud extending through the closer body, wherein the vertical pinion provides sufficient rotational force to move the door from an opened position to a closed position;
- a closer arm having an attachment fixture on one end of the closer arm attachable to the vertical pinion connecting stud and a slide fixture on an opposite end of the closer arm insertable into the slide track;
- an optional expander attachable to the lower horizontal rail;
- a latch mechanism having latching components attachable to at least one of the vertical stiles in either an internal or an external configuration;
- a vertical latch frame having optional fixtures to receive the latching components of the latch mechanism;
- a vertical hinge frame attachable to at least one of the vertical stiles to provide either a left or right hinged door;
- an optional cover attachable to the drip cap to conceal at least one of the closer pockets;
- an optional hold-open stop in the slide track;
- an optional linked, segmented closer arm; and
- an optional screen insert, or one more glass inserts, or both.
Those skilled in the art will readily recognize that this embodiment of a door assembly may be configured and/or oriented for either a left hinged or a right hinged installation as described above.
Such door assembly kits may be for a full view door, a high view door, or a mid-view door a as well as an interchangeable door or a self-storing door. For example, in some embodiments the glass and screen panels may be exchanged seasonally. Alternatively, the glass and screen panels may be stored in designated sections of the door and either the glass or screen may be moved into place when it is desired to have either the screen or the glass in view.
In another alternative embodiment, this disclosure describes a method of mounting a door within a framed opening comprising:
a) providing a door assembly comprising:
-
- 1) a door having first and second vertical stiles attached to upper and lower horizontal rails;
- 2) a horizontal slide track associated with the upper horizontal rail;
- 3) a drip cap having a horizontal body with first and second ends optionally having two closer pockets located in regions of the horizontal body adjacent to the first and second ends, an internal channel extending between the first and second end, a closer pocket in a center region of the horizontal body between the first and second ends, or one closer pocket located in a region of the horizontal body adjacent one of the ends of the drip cap;
- 4) a closer insertable into one of the pockets or the channel of the drip cap comprising a closer body attachable to the drip cap, and a vertical pinion rotatably connected to an internal biasing mechanism such as a biasing spring and having at least one connecting stud extending through the closer body, wherein the vertical pinion provides sufficient rotational force to move the door from an opened position to a closed position;
- 5) a closer arm having an attachment fixture on one end of the closer arm attachable to the vertical pinion connecting stud and a slide fixture on an opposite end of the closer arm insertable into the slide track;
- 6) an optional expander attachable to the lower horizontal rail;
- 7) a latch mechanism having latching components attachable to at least one of the vertical stiles in either an internal or external configuration;
- 8) a vertical latch frame having optional fixtures to receive the latching components of the latch mechanism;
- 9) a vertical hinge frame attachable to at least one of the vertical stiles to provide either a left or right hinged door;
- 10) an optional a cover attachable to the drip cap to conceal at least one of the closer pockets;
- 11) an optional hold-open stop in the slide track;
- 12) an optional linked, segmented closer arm; and
- 13) an optional screen insert, or one or more glass inserts, or both;
b) inserting the slide fixture and optional hold-open stop into the slide track;
c) attaching the vertical hinge stile of the door assembly to a door jamb with the vertical hinge frame;
d) inserting the closer into one of the pockets or the channel in the drip cap;
e) attaching the closer arm to one of the closer pinion connecting studs;
f) attaching the drip cap to a door header;
g) attaching the vertical latch frame to the door jamb adjacent the vertical latch stile
h) attaching the latch mechanism externally to or internally in the vertical latch stile;
i) attaching the closer arm to the slide fixture;
j) attaching the optional cover to the drip cap to conceal at least one of the unused closer pockets;
k) attaching the optional expander to the lower horizontal rail; and
l) attaching the screen insert and/or one or more glass inserts in the door.
In some of the embodiments of this method, the installer will decide to install the door assembly as either a left hinged or right hinged door. In embodiments where the door is essentially symmetrical about a horizontal axis, the installer would understand or be instructed to rotate the door assembly 180° from top to bottom in order to allow either a left hinged or a right hinged installation of the door assembly. In other embodiments where the door is essentially symmetrical about a vertical axis, the installer would understand or be instructed to configure and/or orient the door assembly in order to allow either a left hinged or a right hinged installation of the door assembly.
FIGS. 1A and 1B are exploded exterior front views of a left hinged door assembly (1A) and a right hinged door assembly (1B). Each door assembly in FIGS. 1A and 1B includes a door assembly, closer, drip cap having two closer pockets, lock set, vertical latch frame, vertical hinge frame and lower rail expander.
FIGS. 2A and 2B are exploded exterior front views of a left hinged door assembly (2A) and a right hinged door assembly (2B). Each door assembly in FIGS. 2A and 2B includes a door assembly, closer, drip cap having a centered closer pocket, lock set, vertical latch frame, vertical hinge frame and lower rail expander.
FIGS. 3A and 3B are exploded exterior front views of a left hinged door assembly (3A) and a right hinged door assembly (3B). Each door assembly in FIGS. 3A and 3B includes a door assembly, closer, drip cap with a single closer pocket, lock set, vertical latch frame, vertical hinge frame and lower rail expander.
FIGS. 4A and 4B are front views of a left hinged door closer (4A) and closer arm and a right hinged door closer and closer arm (4B).
FIG. 5 is a perspective view of a door closer fitted in a downward facing opening in u-shaped channel in a drip cap.
FIG. 6 is a cut away side view of the door assembly of FIG. 5 having a door closer fitted in a downward facing opening u-shaped channel in a drip cap.
FIG. 7 is a perspective view of a hidden door closer fitted in an upward facing opening in a u-shaped channel in a drip cap.
FIG. 8 is a cut away side view of the door assembly of FIG. 7 having a door closer fitted in an upward facing opening u-shaped channel in a drip cap.
FIG. 9 is a perspective view of a slide track associated with an upper rail of a left hinged door assembly.
FIG. 10 is an exploded perspective view of an embodiment of a door closer.
FIG. 11 is an exploded perspective view of an alternative embodiment of a door closer.
FIG. 12 is a perspective view of a door closer similar to FIG. 5, with a closer arm having two or more linked segments where the door closer is fitted in a downward facing opening in u-shaped channel in a drip cap.
FIG. 13A illustrates a door with an exchangeable screen insert installed.
FIG. 13B illustrates a door with an exchangeable full view glass insert installed.
FIG. 14A illustrates a door with an upper slidable glass panel and a lower glass panel.
FIG. 14B illustrates the door of FIG. 14A with the upper slidable glass panel in an intermediate position, revealing and/or extending a screen panel.
FIG. 14C illustrates the door of FIGS. 14A and 14B in a fully open screen configuration, with an upper slidable glass panel stored in a designated section of the door proximate to a lower glass panel.
The present disclosure is generally directed to a door assembly having a concealed or hidden door closer. In particular, the door closer may be is inserted in a pocket in a drip cap of the door assembly mounted to the upper header of a door frame. The inserted door closer is attached to a closer arm that is connected to a slide fixture inserted into a slide track that is associated with, or a part of, an upper horizontal rail of a door assembly. In use, the door closer provides sufficient force to the closer arm to move the door from an opened position to a closed position. Commonly owned pending applications that report various embodiments of a door with a hidden closer include U.S. patent application Ser. No. 15/382,275 filed Dec. 16, 2016; Ser. No. 15/911,639 filed Mar. 5, 2018; and Ser. No. 15/911,690 filed Mar. 5, 2018.
FIGS. 1A and 1B illustrate an embodiment of a door assembly that may be installed as either a left hinged or a right hinged door. The door assembly components in FIG. 1A include left hinged door frame 1 having vertical latch stile 10, vertical hinge stile 12, vertical hinge frame 13, upper horizontal rail 14 and lower horizontal rail 16. In this embodiment, vertical latch stile 10 includes a latch mechanism pocket 11 for fitting latch mechanism 18 to the latch stile 10. In addition, lower and upper horizontal rails 14 and 16 would be associated with a slide track (not visible) such as an integral slide track or a slide track fitted to one or both of the horizontal rails, for example, during installation. Other door assembly components illustrated in FIG. 1A include closer 20, closer arm 22 which in use moves the door from an open position to a closed position, and drip cap 24. Drip cap 24 includes two pockets 26 and 28 located near each end of the drip cap. Pockets 26 and 28 are used to fit or house closer 20 within the drip cap. FIG. 1A also illustrates vertical latch frame 30 and expander 32. Vertical latch frame 30 combines with latch mechanism 18 to latch and/or securely lock the door in closed position. Expander 32 may be fitted to the lower horizontal rail to adjust the bottom of the door to provide a desired seal between the door and the door threshold of the framed door opening.
The door assembly components in FIG. 1B generally correspond to the components of FIG. 1A, except that the door assembly is configured as a right hinged door. The conversion is readily accomplished because the components are essentially symmetrical about the A-A section line illustrated in FIG. 1A, allowing the door frame to be rotated 180° top-to-bottom to convert the left hinged door of FIG. 1A into the right hinged door of FIG. 1B (or vice versa). In FIG. 1B, reference numerals are the same for the same components of the door assemblies of FIG. 1A. Briefly, the door assembly components in FIG. 1B include right hinged door frame 2 having vertical latch stile 10, vertical hinge stile 12, vertical hinge frame 13, upper horizontal rail 16 and lower horizontal rail 14. In this embodiment, vertical latch stile 10 includes a latch mechanism pocket 11 for fitting latch mechanism 18 to the latch stile. In addition, upper and lower horizontal rails 16 and 14 would be associated with a slide track (not visible) as described above. Other door assembly components illustrated in FIG. 1B include closer 20, closer arm 22 which in use move the door from open position to a closed position as described above and drip cap 24. Representative embodiments of the closer arm 22 include a single segment closer arm 41 as shown in FIG. 5, or a closer arm 41 with two or more linked segments 41a, 41b as shown in FIG. 12. Drip cap 24 includes two closer pockets 26 and 28 located near each end of the drip cap. Closer pockets 26 and 28 are used to fit or house closer 20 within the drip cap. FIG. 1B also illustrates vertical latch frame 30 and expander 32. Vertical latch frame 30 combines with latch mechanism 18 to latch and/or securely lock the door in closed position. Expander 32 may be fitted to the lower horizontal rail to adjust the bottom of the door frame to provide a desired seal between the door and the door threshold of the framed door opening.
The door assembly components in FIGS. 13A and 13B generally correspond to the components of FIGS. 1A and 1B, except that the door of the door assembly comprises seasonably exchangeable inserts, which can include glass, and/or screen panel(s). FIG. 13A illustrates a door with an exchangeable screen insert installed, and FIG. 13B illustrates a door with an exchangeable full view glass insert installed. In FIGS. 13A and 13B, reference numerals are the same for the same components of the door assemblies of FIGS. 1A and 1B with the addition of the exchangeable glass panel 21, and the exchangeable screen panel 23.
The door assembly components in FIGS. 14A, 14B, and 14C generally correspond to the components of FIGS. 1A and 1B, except that the door of the door assembly comprises glass, and/or screen panel(s) storable in designated sections of the door. FIG. 14A illustrates a door with an upper slidable glass panel 15 and a lower glass panel 17, and FIG. 14B illustrates the door of FIG. 14A with the upper slidable glass panel 15 in an intermediate position, revealing and/or extending screen panel 19. FIG. 14C illustrates the door of FIGS. 14A and 14B in a fully open screen configuration, with upper slidable glass panel 15 stored in a designated section of the door proximate to lower glass panel 17. In FIGS. 14A, 14B, and 14C, reference numerals are the same for the same components of the door assemblies of FIGS. 1A and 1B with the addition of the upper slidable glass panel 15, lower glass panel 17, and screen portion 19.
FIGS. 2A and 2B illustrate an embodiment of a door assembly that may be installed as either a left hinged or a right hinged door. The door assembly components in FIG. 2A include left hinged door frame 3 having vertical latch stile 10, vertical hinge stile 12, vertical hinge frame 13, upper horizontal rail 14 and lower horizontal rail 16. In this embodiment, latch mechanism 18 may be externally mounted to vertical latch stile 10. In addition, upper horizontal rail 14 includes a slide track (not visible), such as an integral slide track or a slide track that is associated with or attached to this upper rail, for example, during installation. Other door assembly components illustrated in FIG. 2A include closer 20, closer arm 22 which in use move the door from an open position to a closed position, and drip cap 24. Drip cap 24 includes one centered pocket 25 located in a center region of the drip cap 24. Pocket 25 is used to fit or house closer 20 within the drip cap 24. FIG. 2A also illustrates vertical latch frame 30 and expander 32. Vertical latch frame 30 combines with latch mechanism 18 to latch and/or securely lock the door in closed position. Expander 32 may be fitted to the lower horizontal rail to adjust the bottom of the door to provide a desired seal between the door and the door threshold of the framed door opening.
The door assembly components in FIG. 2B generally correspond to the components of FIG. 2A, except that the door assembly is configured as a right hinged door. The conversion is readily accomplished because the components are essentially symmetrical about the B-B section line illustrated in FIG. 2A, so that the vertical stiles may be configured and/or oriented as either a latch stile or as a hinge stile while maintaining the original orientation of the door frame. That is, the 180° rotation of the door frame described in conjunction with FIGS. 1B and 1B above is not necessary to convert the hinging of the door from left to right (or vice versa). Briefly, the door assembly components in FIG. 2B include right hinged door frame 4 having vertical latch stile 10, vertical hinge stile 12, vertical hinge frame 13, upper horizontal rail 14 and lower horizontal rail 16 (in FIG. 2B, reference numerals are the same for the same components of the door assembly of FIG. 2A). In this embodiment, latch mechanism 18 may be externally mounted to vertical latch stile 10. In addition, upper horizontal rail 14 includes a slide track (not visible) as described above. Other door assembly components illustrated in FIG. 2B include closer 20, closer arm 22 which in use move the door from open position to a closed position as described above and drip cap 24. Drip cap 24 includes a centered closer pocket 25 located in a centered region of the drip cap 24. Closer pocket 25 is used to fit or house closer 20 within the drip cap 24. FIG. 2B also illustrates vertical latch frame 30 and expander 32. Vertical latch frame 30 combines with external latch mechanism 18 to latch and/or securely lock the door in closed position, or alternatively the installer could cut or drill the vertical stile to receive or be fitted with an internal latch mechanism. Expander 32 may be fitted to the lower horizontal rail to adjust the bottom of the door frame to provide a desired seal between the door and the door threshold of the framed door opening.
FIGS. 3A and 3B illustrate embodiments of a door assembly that may be installed as a left hinged door (FIG. 3A) or as a right hinged door (FIG. 3B), respectively. The door assembly components in FIG. 3A include left hinged door frame 5 having vertical latch stile 10, vertical hinge stile 12, vertical hinge frame 13, upper horizontal rail 14 and lower horizontal rail 16. In this embodiment, latch mechanism 18 may be externally mounted to vertical latch stile 10, or alternatively the installer could cut or drill the vertical stile to receive or be fitted with an internal latch mechanism. In addition, upper horizontal rail 14 includes a slide track (not visible), such as an integral slide track or a slide track that is associated with or attached to this upper rail, for example, during installation. Other door assembly components illustrated in FIG. 3A include closer 20, closer arm 22 which in use move the door from an open position to a closed position, and drip cap 24. Drip cap 24 includes a single pocket 25 located near the end of the drip cap 24 in a region adjacent to the vertical hinge frame. Pocket 25 is used to fit or house closer 20 within the drip cap. FIG. 3A also illustrates vertical latch frame 30 and expander 32. Vertical latch frame 30 combines with latch mechanism 18 to latch and/or securely lock the door in closed position. Expander 32 may be fitted to the lower horizontal rail to adjust the bottom of the door to provide a desired seal between the door and the door threshold of the framed door opening.
The door assembly components in FIG. 3B generally correspond to the components of FIG. 3A, except that the door assembly is configured as a right hinged door. In FIG. 3B, reference numerals are the same for the same components of the door assembly of FIG. 3A. Briefly, the door assembly components in FIG. 3B include right hinged door frame 6 having vertical latch stile 10, vertical hinge stile 12, vertical hinge frame 13, upper horizontal rail 14 and lower horizontal rail 16. In this embodiment, latch mechanism 18 may be either externally or internally mounted to vertical latch stile 10 as described above. In addition, upper horizontal rail 14 includes a slide track (not visible) also as described above. Other door assembly components illustrated in FIG. 3B include closer 20, closer arm 22 which in use moves the door from an open position to a closed position as described above, and drip cap 27. Drip cap 27 includes a single pocket 26 located near the end of the drip cap 24 in a region adjacent to the vertical hinge frame. Pocket 26 is used to fit or house closer 20 within the drip cap 27. FIG. 3B also illustrates vertical latch frame 30 and expander 32. Vertical latch frame 30 combines with latch mechanism 18 to latch and/or securely lock the door in closed position. Expander 32 may be fitted to the lower horizontal rail to adjust the bottom of the door frame to provide a desired seal between the door and the door threshold of the framed door opening.
FIGS. 4A and 4B illustrate a closer 100 that may be used in both a left hinged or right hinged door. This illustrated closer 100, for example, may be used with door assemblies illustrated in FIGS. 1-3. The closer in FIGS. 4A and 4B has a closer body 101, a set of mounting tabs 102 and 103, and upper and lower connecting studs 104 and 105. FIGS. 4A and 4B also illustrate closer arm 106 and slide attachment fixture 107. In use, mounting tabs 102 and 103 attach the closer body to a drip cap (not shown). Connecting studs 104 and 105 are attached to an internal pinion (not shown) in the closer body which provides rotational force to the connecting studs. When the closer arm 106 is attached to one of the connected studs, a rotational force is transmitted to closer arm 106 in order to move the slide fixture 107 in a slide track (not shown) associated with the upper horizontal rail of the door assembly. The rotational movement of the closer arm 106 provides a force to move a door from an opened to closed position when the door is used. The closer 100, closer arm 106 and slide fixture 107 may be used in either a left hinged door or a right hinged door depending on the configuration and orientation of the closer in the pocket in the drip cap. In particular, when the closer body 101 is attached to the drip cap with mounting tabs 102 and 103 in a pocket in the drip cap adjacent the vertical hinge stile region of the door with connecting stud 105 in a downward orientation as shown in FIG. 4A, the closer may be used in a left hinged door.
If the closer body is inverted and rotated end-for-end and inserted into a pocket (or channel, as described below) in the drip cap adjacent the vertical hinged stile region of the door with connecting stud 104 in a downward orientation as shown in FIG. 4B, the closer may be used in a right hinged door. The two different orientations of the closer 100 for use in either a left or right hinged door are further illustrated by the use of phantoms lines in both figures. The upper phantom lines illustrate the closer arm and slider fixture for the alternative hinged positons. The phantom closer arm and slider attachment fixture illustrated in FIG. 4A set out a configuration of a right hinged door. Similarly, the phantom closer arm and slider fixture illustrated in FIG. 4B set out a configuration for a left hinged door. The specific orientation of the closer body also provides a particular rotation of the pinion and connecting studs. Specifically, when connecting stud 105 is in a downward orientation the connecting stud will rotate in one direction, for example in a clockwise direction. In contrast, when the connected stud 106 is in a downward orientation the connecting stud will rotate in the opposite direction, for example in a counterclockwise direction.
Those skilled in the art will readily recognize that alternate configurations for closer 100 are possible. For example, closer 100 could be configured such that connecting studs 104 and 105 are attached to separate internal pinions (not shown), and both extend through the same side of closer body 100, with one pinion and stud configured to rotate in a clockwise direction and the other pinion and stud configured to rotate in a counterclockwise direction. Closer 100, closer arm 106, and slide fixture 107 would be able to be used for both right hinged and left hinged doors by attaching the closer arm 106 to the appropriate connecting stud.
In some embodiments, the door assemblies of this disclosure may be fitting or attached in a closer pocket included in the drip cap. In other embodiments, the drip cap may be configured as a u-shaped groove that extends between each of the ends of the drip cap. Further, the u-shaped drip cap may have the open section of u-shaped channel facing downward toward the upper rail of the door frame or, alternatively the section of the u-shaped channel may face upwards away from the upper rail of the door frame.
FIG. 5 illustrates a drip cap having a u-shaped channel that extends between each of the ends of the drip cap. In this illustrated embodiment, the open section of the u-shaped channel faces downward toward the upper rail of the door frame. Specifically, FIG. 5 shows drip cap 34 having an open channel 35 extending between each end 36 and 37 of the drip cap. The open section of the channel in the drip cap faces the upper rail 39 of the door. FIG. 5 further illustrates door closer 40 fitted or housed in channel 35, as well as closer arm 41 secured to the closer and slide fixture inserted in the slide track associated with the upper rail of the door. FIG. 12 illustrates an embodiment substantially similar to the closer illustrated in FIG. 5 with the exception that in FIG. 12 the closer arm 41 comprises two (or more) linked segments 41a and 41b in place of a closer arm 41 that comprises a single segment as shown in FIG. 5.
FIG. 6 is a side view cross section that illustrates the closer body 60 inserted into a downward opening channel 62 of the drip cap 61. This view also illustrates the slide fixture 64 inserted in the slide track 66 associated with the upper rail of the door.
FIG. 7 illustrates an alternative embodiment of a drip cap having a u-shaped channel that extends between each of the ends of the drip cap. In this embodiment, the open section of the u-shaped channel faces upward away from the upper rail of the door. FIG. 7 shows a drip cap 42 with a u-shaped channel 43 extending between the ends 44 and 45 of the drip cap. A door closer (not visible) is hidden or concealed in the channel. A connecting stud 46 of the hidden closer extends downward through an opening in drip cap 42 and is is attached or secured to the closer arm 48. The closer arm 48 is also attached or secured to the slide fixture inserted in the slide track associated with the upper rail 47 of the door frame.
FIG. 8 is a side view cross section that illustrates the closer body 80 inserted into an upward opening channel 82 of the drip cap 81. This view also illustrates the slide fixture 84 inserted in the slide track 86 associated with the upper rail of the door frame.
FIG. 9 illustrates closer arm 90 attached to slide fixture 92 inserted into slide track 94 and hold-open stop 95 that are associated with the upper horizontal rail of the door frame. Hold-open stop 95 also fitted or inserted in slide track 94 and functions to limit the door swing when the door is moved to its most open position, and can keep the door in a fixed stay-open position, if desired, and then can be released from the stay-open position for the door to close.
Those skilled in the art will readily recognize that alternate configurations for closer arm 90 and slide fixture 92 are possible. For example, while FIG. 9 depicts a closer arm comprised of a single segment, closer arms comprised of two or more linked segments are also possible. Where linked segments are utilized, the segment farthest from the connecting stud may be connected to slide fixture 92 which is fitted or inserted into a slide track 94, or may be connected directly to the door frame without the use of a slide fixture or slide track.
FIG. 10 is an exploded perspective view of a mechanical spring closer 100. This closer includes a closer body 101 and mounting tabs 102 and 103. Mechanical biasing spring 104 is fitted in closer body 101 and connected to exert a force on geared rack 105. Geared pinion 106 is rotatably mounted in the closer body and is engaged with the geared rack to provide rotational motion as the rack is moved linearly. Geared pinion 106 includes connecting stud 107 which may be connected to a closer arm (not shown). As the connected closer arm is moved by opening and closing the door assembly (not shown), gear pinion 106 rotates and linearly displaces rack 105. The movement of the rack imparts a compressive force to spring 104. When the door assembly is released from an open position, sufficient force is transferred by the spring through the rack 105 and pinion 106 to the closer arm to move the door frame from the open position to the closed position by the rotation of the geared pinion and the resulting movement of the closer arm.
FIG. 11 is an exploded perspective view of gas spring closer 110. The components of this embodiment, including closer body 111 and mounting tabs 112 and 113, are substantially similar to the closer illustrated in FIG. 10 with the exception that the mechanical spring of FIG. 10 is replaced with gas spring 114. Gas spring 114 provides a similar force to geared rack 115 and geared pinion 116 as the geared pinion is rotated by the movement of a closer arm (not shown) which is connected to the geared pinion by connecting stud 117.
Those skilled in the art will readily recognize that any of the arrangements of door assemblies, latch and hinge frames, latch mechanisms, and expanders depicted in FIGS. 1A and 1B, 2A and 2B, and 3A and 3B can be combined with any of the arrangements of closers and drip caps depicted in FIGS. 1A and 1B, 2A and 2B, 3A and 3B, 5, 6, 7, and 8 to provide a left or right handed door with a closer concealed in a drip cap.
2 Pockets in Drip Cap
1. A first embodiment of a door assembly, comprising:
-
- a door having first and second vertical stiles attached to upper and lower horizontal rails;
- a horizontal slide track associated with the upper horizontal rail;
- a drip cap having a horizontal body with first and second ends having two closer pockets located in regions of the horizontal body adjacent to the first and second ends;
- a closer insertable into one of the pockets of the drip cap comprising a closer attachable to the drip cap, and a pinion rotatably connected to an internal biasing mechanism such as a biasing spring and having at least one connecting stud extending through the closer body, wherein the pinion provides sufficient rotational force to move the door from an opened position to a closed position; and
- a closer arm having an attachment fixture on one end of the closer arm attachable to the pinion connecting stud and a slide fixture on an opposite end of the closer arm insertable into the slide track.
Channel in Drip Cap
2. A second embodiment of a door assembly, comprising:
- a door having one or more vertical stiles attached to upper and lower horizontal rails;
- a horizontal slide track associated with the upper horizontal rail;
- a drip cap having a horizontal body with first and second ends having an internal channel extending between the first and second ends;
- a closer insertable into the internal channel of the drip cap comprising a closer body attachable to the drip cap, and a pinion rotatably connected to an internal biasing mechanism such as a biasing spring and having at least one connecting stud extending through the closer body, wherein the pinion provides sufficient rotational force to move the door from an opened position to a closed position; and
- a closer arm having an attachment fixture on one end of the closer arm attachable to the pinion connecting stud and a slide fixture on an opposite end of the closer arm insertable into the slide track.
Center Pocket in Drip Cap
3. A third embodiment of a door assembly, comprising:
- a door having first and second vertical stiles attached to upper and lower horizontal rails;
- a horizontal slide track associated with the upper horizontal rail;
- a drip cap having a horizontal body with first and second ends having a closer pocket in a center region of the horizontal body between the first and second ends;
- a closer insertable into the pocket of the drip cap comprising a closer body attachable to the drip cap, and a pinion rotatably connected to an internal biasing mechanism such as a biasing spring and having at least one connecting stud extending through the closer body, wherein the pinion provides sufficient rotational force to move the door from an opened position to a closed position; and
- a closer arm having an attachment fixture on one end of the closer arm attachable to the pinion connecting stud and a slide fixture on an opposite end of the closer arm insertable into the slide track.
Left or Right Hinged Door with Pocket in Drip Cap
4. Fourth and fifth embodiments of a door assembly for either a left or right hinged door with pocket in a drip cap comprising:
- a door having first and second vertical stiles attached to upper and lower horizontal rails;
- a horizontal slide track associated with the upper horizontal rail;
- a drip cap having a horizontal body with first and second ends having one closer pocket located in a region of the horizontal body adjacent one of the ends of the drip cap for either a left hinged or a right hinged door assembly;
- a closer insertable into the pocket of the drip cap comprising a closer body attachable to the drip cap, and a pinion rotatably connected to an internal biasing mechanism such as a biasing spring and having at least one connecting stud extending through the closer body, wherein the pinion provides sufficient rotational force to move the door from an opened position to a closed position; and
- a closer arm having an attachment fixture on one end of the closer arm attachable to the pinion connecting stud and a slide fixture on an opposite end of the closer arm insertable into the slide track.
5. A sixth embodiment of a door assembly kit, the door assembly kit comprising:
- a door having first and second vertical stiles attached to upper and lower horizontal rails;
- a horizontal slide track associated with the upper horizontal rail;
- a drip cap having a horizontal body with first and second ends optionally having two closer pockets located in regions of the horizontal body adjacent to the first and second ends, an internal channel extending between the first and second end, a closer pocket in a center region of the horizontal body between the first and second ends, or one closer pocket located in a region of the horizontal body adjacent one of the ends of the drip cap;
- a closer insertable into one of the pockets or the channel of the drip cap comprising a closer body attachable to the drip cap, and a pinion rotatably connected to an internal biasing mechanism such as a biasing spring and having at least one connecting stud extending through the closer body, wherein the pinion provides sufficient rotational force to move the door from an opened position to a closed position;
- a closer arm having an attachment fixture on one end of the closer arm attachable to the pinion connecting stud and a slide fixture on an opposite end of the closer arm insertable into the slide track;
- an optional expander attachable to the lower horizontal rail;
- a latch mechanism having latching components attachable to at least one of the vertical stiles in either an internal or an external configuration;
- a vertical latch frame having optional fixtures to receive the latching components of the latch mechanism;
- a vertical hinge frame attachable to at least one of the vertical stiles to provide either a left or right hinged door;
- an optional cover attachable to the drip cap to conceal at least one of the closer pockets;
- an optional hold-open stop in the slide track;
- an optional linked, segmented closer arm; and
- an optional screen insert, or one or more glass inserts, or both.
6. The door assembly of embodiments 1-5 or door kit of embodiment 6, wherein the door is a full view door, a high view door, or a mid-view door.
7. The door assembly of embodiments 1-5 or door kit of embodiment 6, wherein the door comprises seasonably exchangeable glass and/or screen panels, or glass and/or screen panels storable in designated sections of the door.
8. The door assembly of embodiments 1-5 or door kit of embodiment 6 further comprising a vertical hinge frame attached to at least one of the vertical stiles.
9. The door assembly of embodiments 1-5 or door kit of embodiment 6 further comprising a latch mechanism having latching components attachable to at least one of the vertical stiles.
10. The door assembly or door kit of embodiment 9 wherein the latch mechanism is externally mounted to at least one of the vertical stiles.
11. The door assembly or door kit of embodiment 9, wherein the latch mechanism is internally mounted in a latch pocket in at least one of the vertical stiles.
12. The door assembly of embodiments 1-5 or door kit of embodiment 6 further comprising a vertical latch frame attached to a door jamb adjacent at least one of the vertical stiles and having optional fixtures to receive the latching components of the latch mechanism.
13. The door assembly of embodiments 1-5 or door kit of embodiment 6, wherein the slide track is an integral component of the upper horizontal rail of the door frame.
14. The door assembly of embodiments 1-5 or door kit of embodiment 6, wherein the slide track is a component attachable to the upper horizontal rail of the door frame.
15. The door assembly of embodiments 1-5 or door kit of embodiment 6 further comprising an expander attachable to the lower horizontal rail.
16. The door assembly of embodiments 1-5 or door kit of embodiment 6, wherein the internal biasing mechanism provides a torsional force or linear force.
17. The door assembly of embodiments 1-5 or door kit of embodiment 6, wherein the closer closes the door at a consistent speed or a variable speed.
18. The door assembly of embodiments 1-5 or door kit of embodiment 6, wherein the pinion has upper and lower connecting studs extending through a top and bottom of the closer body, and wherein the connecting stud rotates clockwise when the closer is in a first orientation in the closer pocket or channel, and counterclockwise when the closer is in a second orientation in the closer pocket or channel, or wherein the pinion has two connecting studs extending through either the top or bottom of the closer body, and wherein one connecting stud rotates clockwise when the closer is in the closer pocket or channel, and the other connecting stud rotates counterclockwise when the closer is in the closer pocket or channel.
19. The door assembly of embodiments 1-5 or door kit of embodiment 6, wherein the connecting stud rotates either clockwise or counterclockwise when displaced from a center biased position.
20. The door assembly of embodiments 1-5 or door kit of embodiment 6, wherein the closer comprises a dampener.
21. The door assembly of embodiment 1 or door kit of embodiment 6 further comprising a cover attachable to the drip cap to conceal an unused closer pocket.
22. The door assembly or door kit of embodiments 1-3 or 5, wherein the door frame can be installed as a left or right hinged door.
23. An embodiment of a method of mounting a door within a framed opening comprising:
a) providing a door assembly comprising:
- 1) a door having first and second vertical stiles attached to upper and lower horizontal rails;
- 2) a horizontal slide track associated with the upper horizontal rail;
- 3) a drip cap having a horizontal body with first and second ends optionally having two closer pockets located in regions of the horizontal body adjacent to the first and second ends, an internal channel extending between the first and second end, a closer pocket in a center region of the horizontal body between the first and second ends, or one closer pocket located in a region of the horizontal body adjacent one of the ends of the drip cap;
- 4) a closer insertable into one of the pockets or the channel of the drip cap comprising a closer body attachable to the drip cap, and a pinion rotatably connected to an internal biasing mechanism such as a biasing spring and having at least one connecting stud extending through the closer body, wherein the pinion provides sufficient rotational force to move the door from an opened position to a closed position;
- 5) a closer arm having an attachment fixture on one end of the closer arm attachable to the pinion connecting stud and a slide fixture on an opposite end of the closer arm insertable into the slide track;
- 6) an optional expander attachable to the lower horizontal rail;
- 7) a latch mechanism having latching components attachable to at least one of the vertical stiles in either an internal or external configuration;
- 8) a vertical latch frame having optional fixtures to receive the latching components of the latch mechanism;
- 9) a vertical hinge frame attachable to at least one of the vertical stiles to provide either a left or right hinged door;
- 10) an optional cover attachable to the drip cap to conceal at least one of the closer pockets;
- 11) an optional hold-open stop in the slide track;
- 12) an optional linked, segmented closer arm; and
- 13) an optional screen insert, or one or more glass inserts, or both;
b) inserting the slide fixture and optional hold-open stop into the slide track;
c) attaching the vertical hinge stile of the door assembly to a door jamb with the vertical hinge frame;
d) inserting the closer into one of the pockets or the channel in the drip cap;
e) attaching the closer arm to one of the closer pinion connecting studs;
f) attaching the drip cap to a door header;
g) attaching the vertical latch frame to the door jamb adjacent the vertical latch stile
h) attaching the latch mechanism externally to or internally in the vertical latch stile;
i) attaching the closer arm to the slide fixture;
j) attaching the optional cover to the drip cap to conceal at least one of the unused closer pockets;
k) attaching the optional expander to the lower horizontal rail; and
l) attaching the screen insert and/or one or more glass inserts in the door.
24. The method of embodiment 23, wherein the door is a full view door, a high view door, or a mid-view door.
25. The method of embodiment 23, wherein the door comprises seasonably exchangeable glass and/or screen panels, or glass and/or screen panels storable in designated sections of the door.
26. The method of embodiment 23, wherein the door can be installed as a left or right hinged door.
27. The method of embodiment 23 further comprising a vertical hinge frame attached to at least one of the vertical stiles.
28. The method of embodiment 23 further comprising a latch mechanism having latching components attachable to at least one of the vertical stiles.
29. The method of embodiment 28, wherein the latch mechanism is externally mounted to at least one of the vertical stiles.
30. The method of embodiment 28, wherein the latch mechanism is internally mounted in a latch pocket in at least one of the vertical stiles.
31. The method of embodiment 23 further comprising a vertical latch frame attached to a door jamb adjacent at least one of the vertical stiles and having optional fixtures to receive the latching components of the latch mechanism.
32. The method of embodiments 23, wherein the slide track is an integral component of the upper horizontal rail of the door frame.
33. The method of embodiment 23, wherein the slide track is a component attachable to the upper horizontal rail of the door frame.
34. The method of embodiment 23 further comprising an expander attachable to the lower horizontal rail.
35. The method of embodiment 23, wherein the internal biasing mechanism provides a torsional force or linear force.
36. The method of embodiment 23, wherein the closer closes the door at a consistent speed or a variable speed.
37. The method of embodiment 23, wherein the pinion has upper and lower connecting studs extending through a top and bottom of the closer body, and wherein the connecting stud rotates clockwise when the closer is in a first orientation in the closer pocket or channel, and counterclockwise when the closer is in a second orientation in the closer pocket or channel.
38. The method of embodiment 23, wherein the pinion has two connecting studs extending through either the top or bottom of the closer body, and wherein one connecting stud rotates clockwise when the closer is in a the closer pocket or channel, and the other connecting stud rotates counterclockwise when the closer is in the closer pocket or channel.
39. The method of embodiment 23, wherein the connecting stud rotates either clockwise or counterclockwise when displaced from a center biased position.
40. The method of embodiment 23, wherein the closer comprises a dampener.
41. The door assembly of embodiments 1-5, the door kit of embodiment 6, or the method of embodiment 23, wherein the closer comprises one or more mounting tabs fastened to the closer body to attach the closer to the drip cap.
Kondratuk, Michael W., Dixon, Alan M., Lee, Allen E., Nordgaard, Kelly D., Richter, Jordan A., Stratmoen, Todd N., Zacher, Bryan P.
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| Executed on | Assignor | Assignee | Conveyance | Frame | Reel | Doc |
| Oct 11 2016 | RICHTER, JORDAN A | LARSON MANUFACTURING COMPANY OF SOUTH DAKOTA, INC | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 054208 | /0517 |
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| Oct 18 2016 | LEE, ALLEN E | LARSON MANUFACTURING COMPANY OF SOUTH DAKOTA, INC | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 054208 | /0517 |
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| Oct 20 2016 | DIXON, ALAN M | LARSON MANUFACTURING COMPANY OF SOUTH DAKOTA, INC | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 054208 | /0517 |
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| Oct 20 2016 | KONDRATUK, MICHAEL W | LARSON MANUFACTURING COMPANY OF SOUTH DAKOTA, INC | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 054208 | /0517 |
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| Oct 20 2016 | NORDGAARD, KELLY D | LARSON MANUFACTURING COMPANY OF SOUTH DAKOTA, INC | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 054208 | /0517 |
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| Oct 20 2016 | STRATMOEN, TODD N | LARSON MANUFACTURING COMPANY OF SOUTH DAKOTA, INC | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 054208 | /0517 |
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| Oct 20 2016 | ZACHER, BRYAN P | LARSON MANUFACTURING COMPANY OF SOUTH DAKOTA, INC | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 054208 | /0517 |
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| Dec 20 2016 | | Larson Manufacturing Company of South Dakota, LLC | (assignment on the face of the patent) | | / |
| Dec 04 2020 | LARSON MANUFACTURING COMPANY OF SOUTH DAKOTA, INC | Larson Manufacturing Company of South Dakota, LLC | ENTITY CONVERSION | 055582 | /0362 |
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